JP5608417B2 - Motor and motor manufacturing method - Google Patents

Description

  The present invention relates to a motor and a method for manufacturing the motor.

  An inner rotor type motor is configured such that a rotor is disposed in a space formed inside an annular stator, and the rotor is rotatable with respect to the stator. A coil is wound around a slot formed between adjacent teeth of a stator core constituting the stator. Distributed winding and concentrated winding are known as winding methods of the coil. Generally, it is easier to maintain a high torque density by winding a coil with distributed winding. Therefore, distributed winding is often employed in motors that require high torque.

  In the distributed winding, a coil is wound so as to span between slots separated by a predetermined distance. For example, in the case of a three-phase motor, the U-phase, V-phase, and W-phase coils are arranged so as to cross each other at the coil transition portion (corresponding to the coil end portion of the present application). Here, it is necessary to ensure electrical insulation between the phases at the coil end. For example, in Patent Document 1, interphase insulating paper (insulation of the present application) having a vertical leg portion inserted into a slot of the stator core and a horizontal leg portion (corresponding to the first insulating portion of the present application) disposed outside the stator core. The electrical insulation between each phase at the coil end is ensured by using a paper member.

JP 2008-228506 A

  By the way, in patent document 1, the vertical leg part of interphase insulation paper is inserted in the slot of a stator core, and is pressed and fixed by the coil. Further, the horizontal leg portion of the interphase insulating paper is disposed between the coil ends of each phase. That is, the interphase insulating paper is only held between the stator core and the coil. Therefore, there is a possibility that the interphase insulating paper may be displaced from a predetermined position at the time of assembling the coil or after the coil is assembled, or the interphase insulating paper may be dropped in the worst case. Thereby, there exists a possibility that the electrical insulation of the coil of each phase may be impaired. Further, the interphase insulating paper disclosed in Patent Document 1 has an opening surrounded by a vertical leg portion and a horizontal leg portion. Here, the portion punched to form the opening is discarded without being used. Therefore, the yield is deteriorated in the production of the interphase insulating paper of Patent Document 1.

  Then, this invention makes it a subject to provide the motor and the manufacturing method of a motor which can suppress the shift | offset | difference of an insulating paper member.

In order to solve the above-described problems, the motor of the present invention (for example, the motor 23 in the embodiment) includes a split core in which a tooth (for example, the tooth 42 in the embodiment) and a yoke (for example, the yoke 46 in the embodiment) are formed. (For example, the divided core 45 in the embodiment) is connected to a plurality of stator cores (for example, the stator core 41 in the embodiment) formed in an annular shape, and slots formed between the teeth of the adjacent divided cores (for example, A stator including a coil (for example, the coil 20 in the embodiment) partially inserted into the slot 43 in the embodiment, and a rotor (for example, rotatably supported on the inner peripheral side of the stator) And the rotor 22) in the embodiment, wherein the coils are at least a pair. A slot insertion portion (for example, slot insertion portions 53 and 54 in the embodiment) and at least a pair of coil end portions (for example, coil end portions 55 and 56 in the embodiment), and the coil of the coil The end part has an insulating paper member (e.g., the entire circumference in the circumferential direction of the coil (e.g., S direction in the embodiment) in at least a part of the central axis direction (e.g., T direction in the embodiment) of the coil. The insulating paper member 80) in the embodiment is covered and insulated from the coil end portions of the adjacent coils, and the insulating paper member covers the entire circumference of the coil end portion in the circumferential direction of the cross section. Part (for example, the coil end insulating part 80a in the embodiment), the slot insertion part of the coil, and the slot of the stator core. A second insulating portion (for example, the slot insulating portion 80b in the embodiment) disposed between the first insulating portion and the second insulating portion between the first insulating portion and the second insulating portion. And a plurality of the first insulating portions and the second insulating portions alternately along the longitudinal direction of the insulating paper member. The first insulating portion and the second insulating portion that are arranged and adjacent to each other are connected by the connecting portion at adjacent positions .
According to the present invention, the coil end portion is covered with the insulating paper member on the entire circumference in the circumferential direction of the coil in at least a part of the coil in the central axis direction. Thereby, the insulating paper member is wound and held around the entire circumference of the coil end portion in the circumferential direction of the cross section. Therefore, compared with the case where an insulating paper member is pinched | interposed and hold | maintained like patent document 1, it can suppress that an insulating paper member slip | deviates at the time of the assembly | attachment of the coil to a stator core, or the assembly | attachment of a coil.
Further, the first insulating portion is wound and held around the entire circumference of the coil end portion in the circumferential direction of the cross section, and the second insulating portion is held between the coil and the slot. And since the 1st insulating part and the 2nd insulating part are connected by the connection part, it can further suppress that an insulating paper member shifts at the time of the assembly | attachment of the coil to a stator core, or the assembly | attachment of a coil. Further, the second insulating portion can ensure electrical insulation between the stator core and the coil.

The coil end portion of the coil is provided so as to bulge outward in the radial direction of the stator, and the connecting portion of the insulating paper member is provided on the inner side in the radial direction. It is characterized by.

Further, the second insulating portion of the insulating paper member covers the entire circumference of the slot insertion portion in the circumferential direction of the cross section, and the width along the circumferential direction of the cross section when the first insulating portion is developed in a plane. And the width along the circumferential direction of the cross section when the second insulating portion is planarly developed, and the connection portion has a notch (for example, the inner notch portion 84 and the embodiment in the embodiment) It is desirable to provide an outer notch 85).
According to this invention, the 2nd insulating part has covered the perimeter of the cross-section circumferential direction of the slot insertion part of a coil. Therefore, in addition to the first insulating portion, the second insulating portion is also wound and held around the coil, so that the insulating paper member can be further prevented from shifting. Further, the width along the circumferential direction of the cross section when the first insulating portion is flatly developed and the width along the circumferential direction of the cross section when the second insulating portion is flatly developed have substantially the same width. doing. Thereby, a 1st insulating part, a 2nd insulating part, and a connection part can be formed from the insulating paper sheet which has a fixed width | variety, and the waste part of the insulating paper at the time of cutting can be decreased. Therefore, the yield of insulating paper can be improved. In addition, since the notch is provided in the connecting portion, when the insulating paper member is wound along the circumferential direction of the cross section of the coil, it is possible to prevent the insulating paper member from overlapping and stretching at the curved portion of the coil. Thereby, since the insulating paper member can be wound in close contact with the outer periphery of the coil, it is possible to suppress the thickness of the insulating paper member.

In addition, the insulating paper member in the circumferential direction has an overlapping portion formed by overlapping one end portion and the other end portion (for example, the overlapping portion 80c in the embodiment), and the one end portion and the other end portion. It is desirable to have a restricting means (for example, the double-sided tape 67 in the embodiment) that restricts relative movement with respect to the portion.
According to the present invention, the relative movement between the one end portion and the other end portion of the insulating paper member is restricted in the overlapping portion. Therefore, it is possible to prevent the insulating paper member from expanding due to the opening of one end and the other end of the insulating paper member after the coil is covered with the insulating paper member and wound. Thereby, it is possible to prevent the insulating paper member from shifting when the coil is assembled to the stator core or after the coil is assembled.

Further, it is desirable that the overlapping portion of the insulating paper member is in contact with the bottom portion of the slot of the stator (for example, the bottom portion 44 in the embodiment).
According to the present invention, since the overlapping portion is in contact with the bottom of the slot of the stator, the overlapping portion of the insulating paper member is sandwiched between the coil and the bottom of the slot. Thereby, since it can prevent that the one end part and other end part of an insulating paper member open and an insulating paper member expand | deploys, it can further suppress that an insulating paper member slip | deviates.

In addition, the motor manufacturing method of the present invention includes a stator core formed in an annular shape by connecting a plurality of divided cores formed with teeth and yokes, and a slot formed between the teeth of adjacent divided cores. A motor comprising: a stator having a portion inserted therein and a coil assigned to each phase; and a rotor disposed on the inner peripheral side of the stator and rotatably supported. A coil forming step for forming the coil having a slot insertion portion and at least a pair of coil end portions (for example, a coil forming step S10 in the embodiment); A first insulating portion covering the slot, and the slot insertion portion between the slot insertion portion of the coil and the slot of the stator core. A second insulating portion arranged on the Migihitsuji, the a first connection for connecting the insulating portion and the second insulating section part, have a, with developed shape is a strip, the first along the longitudinal direction The insulating paper member in which a plurality of one insulating portions and the second insulating portions are alternately arranged and the adjacent first insulating portions and the second insulating portions are connected by the connecting portions at positions adjacent to each other is used as the coil. Insulating paper member mounting step (for example, insulating paper member mounting step S20 in the embodiment) to be mounted, and a coil placement step for inserting the coil into the slot after the insulating paper member mounting step (for example, coil placement step S30 in the embodiment) ) And a rotor arrangement step (for example, rotor arrangement step S40 in the embodiment) for inserting the rotor on the inner peripheral side of the stator.
According to the present invention, after the insulating paper member mounting step of mounting the insulating paper member on the coil, the coil placement step of inserting and placing the coil in the slot is performed. Therefore, since the coil placement process is performed in a state where the insulating paper member is wound and held on the outer periphery of the coil end portion, it is possible to suppress the insulation paper member from being displaced in the coil placement process.

Further, it is desirable that the second insulating portion covers the entire circumference of the slot insertion portion in the circumferential direction of the cross section.
According to the present invention, since the second insulating part is also wound around the coil and held in addition to the first insulating part, the insulating paper member can be further prevented from shifting.

In the insulating paper member mounting step, an overlapping portion is formed by overlapping one end portion and the other end portion of the insulating paper member in the circumferential direction of the cross section on the slot insertion portion of the coil in the slot insertion portion. In the coil placement step, it is preferable that the overlapping portion is brought into contact with the bottom of the slot.
According to the present invention, since the overlapping portion of the insulating paper member is sandwiched between the coil and the bottom of the slot, it is possible to prevent the insulating paper member from expanding. Therefore, it is possible to further suppress the displacement of the insulating paper member.

  According to the present invention, the coil end portion is covered with the insulating paper member on the entire circumference in the circumferential direction of the coil in at least a part of the coil in the central axis direction. Thereby, the insulating paper member is wound and held around the entire circumference of the coil end portion in the circumferential direction of the cross section. Therefore, compared with the case where an insulating paper member is pinched | interposed and hold | maintained like patent document 1, it can suppress that an insulating paper member slip | deviates at the time of the assembly | attachment of the coil to a stator core, or the assembly | attachment of a coil.

It is a schematic structure sectional view of a motor unit. It is the top view which looked at the stator from the axial direction. It is a perspective view of a stator. It is the top view which looked at the stator core from the axial direction. It is the top view which looked at the split core from the axial direction. It is sectional drawing of a coil. It is sectional drawing in the AA of FIG. It is explanatory drawing of the stator seen from radial direction. FIG. 9A is an explanatory view of an insulating paper member, FIG. 9A is a perspective view of the state in which the insulating paper member is mounted on a coil, and FIG. 9B is a cross-sectional view taken along line BB in FIG. is there. It is a plane development view of an insulating paper member. It is explanatory drawing of the formation apparatus of an insulating paper member. It is a flowchart of the manufacturing process of a motor. FIG. 13A is an explanatory view of an insulating paper member mounting process, FIG. 13A is a perspective view when the insulating paper member is mounted, and FIG. 13B is an explanatory diagram of a mold type. It is explanatory drawing of a coil arrangement | positioning process. It is a perspective view of an insertion jig.

Hereinafter, a motor according to an embodiment of the present invention will be described with reference to the drawings. In the present embodiment, description will be made using a vehicle motor unit mounted on a vehicle.
FIG. 1 is a schematic cross-sectional view of a motor unit according to this embodiment. In the following description, the radial direction of the motor is the R direction, the axial direction of the motor is the Z direction, and the circumferential direction of the motor is the θ direction. If necessary, a cylindrical coordinate system of these R, Z, and θ is used. explain. One side in the Z direction is the + Z side, and the other side is the -Z side. The outer peripheral side in the R direction is the + R side, and the inner peripheral side is the -R side. Further, the clockwise direction when viewed from the + Z side is the + θ side, and the counterclockwise direction is the −θ side.

  As shown in FIG. 1, the motor unit 10 includes a motor housing 11 that houses a motor 23 including a stator 21 and a rotor 22, and a sensor that is fastened to the + Z side of the motor housing 11 and houses a rotation sensor 25 of the motor 23. A housing 13 and a transmission housing 12 that is fastened to the −Z side of the motor housing 11 and accommodates a power transmission unit (not shown) that transmits power from the output shaft 24 of the motor 23 are provided. The motor housing 11 has a motor chamber 36, the mission housing 12 has a mission chamber 37, and the sensor housing 13 has a sensor chamber 38.

(Motor housing)
The motor housing 11 is a member made of aluminum or the like, and is molded by die casting or the like. The motor housing 11 is formed in a substantially cylindrical shape so as to cover the entire motor 23.
A bearing 26 for rotatably supporting one end of the output shaft 24 of the motor 23 is provided on the −Z side of the motor housing 11, and the other end of the output shaft 24 of the motor 23 is provided on the + Z side of the motor housing 11. A bearing 27 is provided for rotatably supporting the. Further, a breather passage 35 communicating with each other is formed in the wall portion 31 of the motor housing 11, the wall portion 32 of the transmission housing 12, and the wall portion 33 of the sensor housing 13. Further, a water jacket 40 for cooling the motor 23 is provided in the wall portion 31 of the motor housing 11 so as to cover the entire circumference of the stator 21 of the motor 23.

(Rotor)
As shown in FIG. 1, a rotor 22 is attached to the outer peripheral surface of the output shaft 24. The rotor 22 is a member made of a magnetic plate such as a substantially disk-shaped electromagnetic steel plate, and is formed by laminating a plurality of magnetic plates formed by pressing. At this time, a convex portion (dwelling) is formed on each magnetic plate by overlapping and caulking each magnetic plate. The dowels can be used to connect and fix the magnetic plates. In addition, you may laminate | stack by adhere | attaching each magnetic board.
The rotor 22 is provided with a through hole through which the output shaft 24 is inserted, and is fixed to the output shaft 24 by press-fitting, for example. As the rotor 22 rotates about the axis, the output shaft 24 can also rotate about the axis at the same time.

(Stator)
FIG. 2 is a plan view of the stator 21 as viewed from the + Z direction.
FIG. 3 is a perspective view of the stator 21.
As shown in FIGS. 2 and 3, the stator 21 of this embodiment includes a stator core 41 formed in an annular shape, and a coil 20 inserted in a slot 43 formed between teeth 42 of adjacent divided cores 45. It is equipped with.

(Stator core)
FIG. 4 is a plan view of the stator core 41 as viewed from the + Z direction.
As shown in FIG. 4, the stator core 41 is configured by connecting a plurality of divided cores 45 in an annular shape. The stator core 41 includes a yoke 46 that forms the outer periphery of the ring, and teeth 42 that are formed to protrude from the yoke 46 toward the center of the ring. A slot 43 is formed between adjacent teeth 42.

FIG. 5 is a plan view of the split core 45 as viewed from the Z direction.
The split core 45 is configured by stacking split core pieces 47 made of electromagnetic steel plates or the like, and the split core pieces 47 are formed by press molding. As shown in FIG. 5, the yoke 46 and the teeth 42 are disposed in the split core 45 so as to be substantially L-shaped when viewed from the Z direction. By forming the stator core 41 (see FIG. 4) with the split core 45, the split core 45 can be press-molded with a better material yield than when the annular stator core 41 is press-molded. The split core 45 is formed by caulking and fixing each split core piece 47 in the same manner as the rotor 22 described above.
A convex portion 51 is formed on the + θ side surface 50 of the yoke 46. A concave portion 49 is formed on the −θ side surface 48 of the yoke 46. The convex portion 51 and the concave portion 49 are configured to be fitted when the split core 45 is connected in an annular shape.

(coil)
FIG. 6 is a perspective view of the coil 20.
7 is a cross-sectional view taken along line AA in FIG.
As shown in FIG. 6 and FIG. 7, the coil 20 is a ring-shaped member formed by winding a conducting wire 52 a plurality of times. In FIG. 6, illustration of both ends of the conducting wire 52 is omitted, but one end of the conducting wire 52 is connected to a neutral point bus ring (not shown), and the other is connected to a three-phase distribution bus ring (not shown). Configured to be connected.

  As shown in FIGS. 6 and 7, the coil 20 has a pair of slot insertion portions 53 and 54 extending along the Z direction. The pair of slot insertion portions 53 and 54 are formed so as to be inclined so that the interval becomes narrower from the + R side toward the −R side when viewed from the Z direction. As shown in FIG. 7, the pair of slot insertion portions 53 and 54 are inclined at an inclination angle α. The inclination angle α is substantially the same as the pole pitch angle formed by the pair of slots into which the pair of slot insertion portions 53 and 54 are inserted. Thus, since the pair of slot insertion portions 53 and 54 are inclined at the inclination angle α, the coil 20 can be disposed along the slots of the stator core formed in an annular shape.

As shown in FIGS. 6 and 7, the coil 20 has a pair of coil end portions 55 and 56 extending from both ends of the slot insertion portions 53 and 54 along the θ direction. The coil end portions 55 and 56 are curved toward the + R side, and are formed in a substantially C shape when viewed from the Z direction.
FIG. 8 is an explanatory view of the stator as viewed from the R direction.
A pair of slope portions 57 and 58 are formed on the pair of coil end portions 55 and 56. As shown in FIG. 8, the slope portions 57 and 58 of this embodiment are inclined so that the distance between the coil end portion 55 and the coil end portion 56 becomes narrower from the slot insertion portion 53 side toward the slot insertion portion 54 side. Is formed. As described above, since the slope portions 57 and 58 are formed in the coil end portions 55 and 56 of the coil 20 of the present embodiment, interference with the coil end portions 55 and 56 of the adjacent other-phase coil 20 is prevented. It can be avoided.

(Insulating paper material)
9 is an explanatory view of the insulating paper member 80, FIG. 9A is a perspective view of the insulating paper member 80 mounted on the coil, and FIG. 9B is a cross-sectional view taken along line BB of FIG. 9A. It is sectional drawing in a line. In the following description, the winding direction of the conducting wire 52 is referred to as a cross-sectional central axis direction (hereinafter referred to as “T direction”). In addition, the circumferential direction of the coil 20 when the cross section is cut along a plane perpendicular to the T direction is referred to as a cross sectional circumferential direction (hereinafter referred to as “S direction”).
FIG. 10 is a plan development view of the insulating paper member 80. The longitudinal direction of the insulating paper member 80 in FIG. 10 corresponds to the T direction in FIG. 9, and one end side in the T direction is the + T side and the other end side is the −T side. Further, the width direction of the insulating paper member 80 corresponds to the S direction in FIG. 9, and one end side in the S direction is the + S side and the other end side is the −S side.
As shown in FIG. 9, the insulating paper member 80 of the present embodiment includes a coil end insulating portion 80 a that covers the coil end portions 55 and 56 of the coil 20 along the S direction of the coil 20, and a slot insertion portion of the coil 20. And a slot insulating portion 80b that covers 53 and 54. The insulating paper member 80 has an overlapping portion 80 c where both ends of the insulating paper member 80 overlap on the + R side of the coil 20, and has a bottom portion 82 on the −R side of the coil 20.

Hereinafter, each part shown in FIG. 9 will be described with reference to a plan development view of the insulating paper member 80 of FIG.
As shown in FIG. 10, the insulating paper member 80 is a sheet-like member whose developed shape is a substantially rectangular shape. The developed insulating paper member 80 has a bottom 82 disposed on the −R side of the coil 20 at the approximate center in the S direction. Further, on the + S side across the bottom portion 82, a coil end outer insulating portion 90a and a slot outer insulating portion 90b that cover the outer peripheral side 90 (see FIG. 9) of the coil 20 are disposed. A coil end inner insulating portion 92a and a slot inner insulating portion 92b covering the inner peripheral side 92 (see FIG. 9) of the coil 20 are disposed on the −S side with the bottom portion 82 interposed therebetween. Further, overlapping margin portions 81a and 81b that overlap at overlapping portions 80c (see FIG. 9) are disposed at both ends of the developed insulating paper member 80 in the S direction. In addition, after winding around the coil 20, the + T side and the −T side of the insulating paper member 80 may be connected or separated.

As shown in FIG. 10, in the developed insulating paper member 80, two coil end insulating portions 80a and slot insulating portions 80b are alternately arranged along the T direction.
The coil end insulating portion 80a and the slot insulating portion 80b have substantially the same width in the S direction. Thereby, as will be described later, the insulating paper member 80 can be formed from a roll of insulating paper sheet having a certain width, and the waste portion of the insulating paper at the time of cutting can be reduced. Therefore, when the insulating paper member 80 is formed, the yield of the insulating paper can be improved.

  The width of the coil end insulating portion 80a and the slot insulating portion 80b in the S direction is longer than the circumferential length of the cross section along the S direction of the coil 20 by the overlapping margin portions 81a and 81b. Thereby, the overlap margin parts 81a and 81b formed at both ends in the S direction of the insulating paper member 80 can be overlapped. Here, the width in the S direction of the overlapping margin portions 81a and 81b is substantially the same as or slightly narrower than the width in the Z direction of the coil end portions 55 and 56 and the width in the θ direction of the slot insertion portions 53 and 54 shown in FIG. Is formed. As a result, as shown in FIG. 9B, the overlapping margin portions 81 a and 81 b do not go around the inner peripheral side 92 and the outer peripheral side 90 of the coil 20, and the insulating paper member 80 covers the entire circumference in the circumferential direction of the coil 20. Can be covered. Therefore, the coil 20 can be prevented from being thickened by the insulating paper member 80.

  Further, the overlapping portion 80c is formed by overlapping the overlapping margin portions 81a and 81b. Here, the relative movement of the overlapping margin portions 81a and 81b of the insulating paper member 80 can be restricted by forming the overlapping portion 80c by sandwiching the double-sided tape between the overlapping margin portions 81a and 81b. Thereby, it is possible to prevent the insulating paper member 80 from expanding due to the opening of the overlapping margin portions 81a and 81b of the insulating paper member 80 after the outer periphery of the coil 20 is covered with the insulating paper member 80 and wound. Note that a double-sided tape is used as the regulating means in this embodiment. However, as long as it is established as temporary fixing until racing or varnish impregnation, any means may be used as the insulating paper regulating means. For example, an adhesive may be used as the regulating means.

  The length of the coil end insulating portion 80a in the T direction is substantially the same as the length of the coil end portions 55 and 56 in the θ direction (see FIG. 9). Thereby, as shown in FIG. 8, substantially the whole coil end parts 55 and 56 can be covered. Therefore, when the coil 20 is inserted into the slot of the stator core 41, electrical insulation from the adjacent coil end portions 55 and 56 of other phases can be secured.

  The length of the slot insulating portion 80b in the T direction is substantially the same as the length of the slot insertion portions 53 and 54 in the Z direction (see FIG. 9). Thereby, as shown in FIG. 8, almost the entire slot insertion portions 53 and 54 can be covered along the Z direction. Therefore, when the coil 20 is inserted into the slot of the stator core 41, electrical insulation between the stator core 41 and the coil 20 can be ensured. As described above, the coil of this embodiment has a pair of slope portions 57 and 58 (see FIG. 8). Therefore, the length in the T direction is different between the slot insulating portion 80 b wound around the slot insertion portion 53 and the slot insulating portion 80 b wound around the slot insertion portion 54.

  As shown in FIG. 10, an inner notch 84 disposed on the inner peripheral side 92 (see FIG. 9) of the coil 20 is provided on the −S side at the boundary portion between the coil end insulating portion 80 a and the slot insulating portion 80 b. Is provided. Further, an outer notch 85 disposed on the outer peripheral side 90 (see FIG. 9) of the coil 20 is provided on the + S side at the boundary portion between the coil end insulating portion 80a and the slot insulating portion 80b.

  The inner notch 84 has a substantially rectangular shape or a substantially platform from the −S side end portion at the boundary between the coil end insulating portion 80a and the slot insulating portion 80b toward the bottom portion 82 disposed substantially at the center in the S direction. It is formed by cutting out into a shape. As a result, as shown in FIG. 9, when the outer periphery of the coil 20 is covered with the insulating paper member 80 and wound, the curve of the coil 20 that becomes the boundary between the slot insertion portions 53 and 54 and the coil end portions 55 and 56 is obtained. It is possible to prevent the insulating paper member 80 from overlapping inside the portion 93. Further, the inner cutout 84 is formed so as to cut out the bottom 82 partially. Thereby, when the insulating paper member 80 is wound so as to cover the outer periphery of the coil 20, wrinkles can be prevented from occurring in the bottom portion 82 of the insulating paper member 80 due to the curved portion 93 of the coil 20. Therefore, since the insulating paper member 80 can be brought into close contact with the coil 20, it is possible to prevent the insulating paper member 80 from becoming thick.

  The outer cutout portion 85 is cut out in a substantially triangular shape having an apex on the + S side of the bottom portion 82 from the + S side end portion of the insulating paper member 80 toward the bottom portion 82 disposed substantially at the center in the S direction. It is formed. As a result, as shown in FIG. 9, it is possible to prevent the insulating paper member 80 from being stretched outside the curved portion 93 when the insulating paper member 80 is wound around the outer periphery of the coil 20. . Further, the substantially triangular apex of the outer notch 85 is formed at a position shifted in the T direction from the notch of the bottom 82 by the inner notch 84. Thereby, the connection part 83 by which the coil end insulation part 80a and the slot insulation part 80b were connected is formed, without dividing the coil end insulation part 80a and the slot insulation part 80b. Thereby, even after the insulating paper member 80 is wound around the coil 20, the coil end insulating portion 80 a and the slot insulating portion 80 b are connected by the connecting portion 83. Therefore, it is possible to prevent the insulating paper member 80 from shifting when the coil 20 is assembled to the stator core or after the coil is assembled.

  Furthermore, a notch 86 is provided in the coil end insulating portion 80a of the insulating paper member 80 of the present embodiment. The notches 86 are formed slightly inward from both ends in the T direction of the coil end insulating portion 80a and toward the bottom portion 82 from the + S side end portion and the −S side end portion. The notches 86 formed at both ends of the coil end insulating portion 80a are formed to be slightly inclined so that the distance between the pair of notches 86 becomes narrower from the end portion in the S direction toward the bottom portion 82. As a result, as shown in FIG. 9, when the insulating paper member 80 covers the outer periphery of the coil 20, the insulating paper member 80 is stretched by the curved portions 94 at both ends in the θ direction of the coil end portions 55 and 56. Can be prevented. In addition, when it is necessary to prioritize varnish impregnation, notches and punching windows (punching) may be added as necessary within a range that can ensure interphase insulation of the coil end portion.

FIG. 11 is an explanatory view of the apparatus for forming the insulating paper member 80 described above.
As shown in FIG. 11, the insulating paper member 80 of this embodiment is formed by being cut out from the insulating paper roll 66 by the insulating paper cutting device 65. Specifically, first, the insulating paper sheet 66a is pulled out from the insulating paper roll 66 by the driving roller 68, and both sides of the insulating paper sheet 66a to be the overlapping margins 81a and 81b (see FIG. 10) are formed on both sides. A tape 67 is affixed. Subsequently, the roller cutter 69 is brought into contact with the insulating paper sheet 66a, and the insulating paper sheet 66a is cut by a cutter blade formed on the outer peripheral surface of the roller cutter 69, whereby the insulating paper member 80 described above is formed. Before attaching the double-sided tape 67, a groove may be formed in the insulating paper sheet 66a using a not-shown grooving roller, and a crease may be formed in the insulating paper sheet 66a using a not-shown folding roller. . By forming a crease in the insulating paper member 80 in advance, the insulating paper member 80 can be easily wound around the coil.

  As described above, the coil end insulating portion 80a and the slot insulating portion 80b have substantially the same width in the S direction (see FIG. 10). Therefore, the coil end insulating portion 80a, the slot insulating portion 80b, and the connecting portion 83 can be formed using the insulating paper roll 66 of the insulating paper sheet 66a having substantially the same width as the developed insulating paper member 80. At this time, only the insulating paper corresponding to the inner notch portion 84 and the outer notch portion 85 removed by the roller cutter 69 becomes a waste portion. Therefore, when the insulating paper member 80 is formed, the waste portion of the insulating paper sheet 66a can be reduced, so that the yield of the insulating paper sheet 66a can be improved.

(Motor manufacturing method)
FIG. 12 is a flowchart of the motor manufacturing process.
As shown in FIG. 12, the motor manufacturing method of this embodiment mainly includes a coil forming step S10 for forming a coil, an insulating paper member mounting step S20 for mounting an insulating paper member on the coil, and an insulating paper member mounting. It has coil arrangement | positioning process S30 which inserts a coil in a slot after a process, and rotor arrangement | positioning process S40 which inserts a rotor in the inner peripheral side of a stator. Below, each process is demonstrated.

(Coil formation process)
In coil formation process S10, as shown in Drawing 6 and Drawing 7, coil 20 which has a pair of slot insertion parts 53 and 54 and a pair of coil end parts 55 and 56 is formed. As a specific method of manufacturing the coil 20, first, the conducting wire 52 is wound around a winding frame (not shown) a predetermined number of times to form a substantially ring-shaped conducting member. Thereby, when the coil 20 is formed later, portions that become the slot insertion portions 53 and 54 and the pair of coil end portions 55 and 56 are formed. Note that the winding frame is preferably made of resin. This can prevent the coil coating from being damaged.
Next, using a coil molding apparatus (not shown), the conductor member is bent in a predetermined direction and molded into a predetermined shape. In the present embodiment, the slot forming portions 53 and 54 are formed so as to have an inclination angle α when viewed from the Z direction by the coil molding apparatus, and the coil end portions 55 and 56 are curved to the + R side (see FIG. 7). ). The coil forming step S10 is thus completed.

(Insulating paper installation process)
FIG. 13 is an explanatory diagram of the insulating paper member mounting step S20, FIG. 13 (a) is a perspective view when the insulating paper member is mounted, and FIG. 13 (b) is an explanatory diagram of a mold type.
Next, an insulating paper member mounting step S20 for mounting the insulating paper member on the coil is performed.
As shown in FIG. 13A, in the insulating paper member mounting step S <b> 20, the coil 20 is set from the −R side of the coil 20 to the insulating paper member 80 in which a fold is formed in advance. The insulating paper member mounting step S20 is performed using the mold 60 shown in FIG. A set groove 61 is formed in the mold 60 along the shape of the coil 20. The set groove 61 has a substantially tapered cross section so that the groove width increases from the −R side to the + R side. The groove width of the set groove portion 61 is formed wider than at least the width in the Z direction (see FIG. 9) of the coil end portions 55 and 56 and the width in the θ direction of the slot insertion portions 53 and 54 (see FIG. 9). Yes. Thereby, the coil 20 can be set from the + R side of the set groove portion 61.
In the insulating paper member mounting step S20, first, as shown in FIG. 13B, the bottom 82 of the insulating paper member 80 is brought into contact with the bottom of the set groove 61 of the mold 60, and the insulating paper member 80 is brought into contact with the set groove 61. Is placed. At this time, the + R side of the insulating paper member 80 opens with a predetermined width K along the tapered surface of the set groove 61.

Subsequently, the coil 20 is set in the set groove 61 of the mold 60 from the + R side of the mold 60. As shown in FIG. 13, the coil 20 is set on the insulating paper member 80 from the −R side of the coil 20. Thus, by setting the coil 20 in the set groove portion 61 of the mold 60, the insulating paper member 80 can be easily disposed on the outer periphery of the coil 20.
Finally, the overlap margin portions 81a and 81b of the insulating paper member 80 are bonded together with the double-sided tape 67 (see FIG. 11) to form an overlap portion 80c (see FIG. 9B), and the overlap margin portions 81a and 81b are relative to each other. Restrict movement. Thereby, it is possible to prevent the insulating paper member 80 from expanding due to the opening of the overlapping margin portions 81a and 81b of the insulating paper member 80 after the outer periphery of the coil 20 is covered with the insulating paper member 80 and wound. As described above, the slot insulating portions 80 b of the insulating paper member 80 are wound around the slot insertion portions 53 and 54 of the coil 20, and the coil end insulating portions of the insulating paper member 80 are wound around the coil end portions 55 and 56 of the coil 20. 80a is wound.

(Coil arrangement process)
FIG. 14 is an explanatory diagram when the coil is inserted in the coil arrangement step S30.
Next, a coil placement step S30 for inserting the coil 20 into the slot 43 of the stator core is performed. In the present embodiment, an eight-pole motor is formed using 24 coils 20, and each coil 20 is assigned to one of three phases, the U phase, the V phase, and the W phase.

As shown in FIG. 14, in the coil arrangement step S <b> 30, the coil 20 around which the insulating paper member 80 is wound is inserted into the slot 43 of the divided core 45 arranged in a band shape. The slot insertion portions 53 and 54 of the coil 20 are disposed in the slot 43 via the slot insulating portion 80 b of the insulating paper member 80. Thereby, electrical insulation between the split core 45 and the coil 20 can be ensured. The coil end portions 55 and 56 of the coil 20 are disposed on the + Z side and the −Z side of the yoke 46 in the split core 45 in a state where the coil end insulating portion 80a of the insulating paper member 80 is wound. Thereby, when the coil 20 of each phase is arrange | positioned, the electrical insulation between the adjacent coils 20 is securable.
Here, the overlapping portion 80 c of the insulating paper member 80 wound around the coil 20 is disposed on the + R side of the coil 20. Therefore, when the coil 20 is inserted into the slot 43, the bottom portion 44 of the slot 43 and the overlapping portion 80c of the insulating paper member 80 come into contact with each other. Thereby, the overlapping portion 80 c of the insulating paper member 80 is sandwiched and held between the coil 20 and the bottom portion 44 of the slot 43. Therefore, it is possible to prevent the overlapping portion 80c of the insulating paper member 80 from opening and the insulating paper member 80 from expanding. In this embodiment, the coil placement step S30 is performed after the insulating paper member mounting step S20. Thereby, since the coil placement step S30 can be performed in a state where the insulating paper member 80 is wound and held around the outer periphery of the coil 20, the insulating paper member 80 can be prevented from being displaced from a predetermined position.

FIG. 15 is a perspective view of the insertion jig.
In the coil arrangement step S30, it is desirable to insert the coil 20 into the slot 43 using the insertion jig 70 shown in FIG.
As shown in FIG. 15, the insertion jig 70 mainly includes a sandwiching portion 75 that sandwiches the coil 20, a movable portion 71 that is pushed in when the coil 20 is pushed out from the sandwiching portion 75, and an interlocking operation with the movable portion 71. Thus, the moving coil 20 is formed from an extruding pin portion 72 that pushes the moving coil 20 out of the holding portion 75.
As a specific method of using the insertion jig 70, first, the sandwiching portion 75 is inserted into the slot 43 while the coil 20 is sandwiched by the sandwiching portion 75. Subsequently, the movable portion 71 is pushed in the direction of the coil 20 to move the push pin portion 72. As a result, the push pin portion 72 pushes the slot insertion portion 53 of the coil 20 from the holding portion 75 and inserts the slot insertion portion 53 into the slot 43 (see FIG. 14). The slot insertion portion 54 is also inserted into the slot 43 by the same operation. At this time, the coil 20 is inserted into the slot 43 through the holding portion 75. By inserting the coil 20 into the slot 43 using the insertion jig 70, the slot 43 and the insulating paper member 80 wound around the coil 20 do not come into contact with each other when the coil 20 is inserted. Therefore, when the coil 20 is inserted, damage to the insulating paper member 80 and displacement of the insulating paper member 80 can be prevented.

(Rotor placement process)
Finally, a rotor arrangement step S40 for inserting the rotor on the inner peripheral side of the stator is performed.
The rotor arrangement step S40 is performed after the belt-like divided core 45 is formed in an annular shape to form the stator 21 (see FIG. 2), and the stator 21 is accommodated in the motor housing. As shown in FIG. 1, the output shaft 24 of the rotor 22 is inserted into bearings 26 and 27, and the rotor 22 on which permanent magnets are arranged is rotatably arranged on the inner peripheral side of the stator 21. Thus, the rotor arrangement step S40 is completed, and the motor manufacturing process is completed.

According to the present embodiment, as shown in FIG. 9, the coil end portions 55 and 56 are covered with the insulating paper member 80 on the entire circumference in the S direction of at least a part of the coil in the T direction. Thus, the insulating paper member 80 is wound and held around the entire circumference in the S direction of the coil end portions 55 and 56. Therefore, as compared with the case where the insulating paper member 80 is sandwiched and held as in Patent Document 1, the insulating paper member 80 is prevented from shifting when the coil 20 is assembled to the stator core or after the coil 20 is assembled. be able to.
In addition to the coil end insulating portion 80a being wound and held around the entire circumference of the coil end portions 55 and 56 in the S direction, the slot insulating portion 80b is held between the coil 20 and the slot 43 and held. Is done. In addition, since the coil end insulating portion 80a and the slot insulating portion 80b are connected by the connecting portion 83, the insulating paper member 80 is further prevented from shifting when the coil 20 is assembled to the stator core or after the coil 20 is assembled. be able to. Further, the slot insulation portion 80b can ensure electrical insulation between the stator core and the coil 20.
Furthermore, as shown in FIG. 10, the width along the S direction when the coil end insulating portion 80a is expanded in plane and the width along the S direction when the slot insulating portion 80b is expanded in plane are substantially the same width. have. Thus, as shown in FIG. 11, the coil end insulating portion 80a, the slot insulating portion 80b, and the connecting portion 83 can be formed from the insulating paper sheet 66a having a certain width, and the waste portion of the insulating paper sheet 66a at the time of cutting Can be reduced. Therefore, the yield of the insulating paper sheet 66a can be improved.

The present invention is not limited to the embodiment described above.
In this embodiment, the coil end insulating part and the slot insulating part are integrally formed, but the coil end insulating part and the slot insulating part may be formed separately. However, the present embodiment is advantageous in that the coupling end is formed by integrally forming the coil end insulating portion and the slot insulating portion, and the insulating paper member can be prevented from shifting.

  The slot insulation part of this embodiment is wound around the slot insertion part of the coil. However, the insulating paper member does not necessarily have to be wound around the coil. For example, the insulating paper member may be disposed between the slot and the coil so as to be along the slot, and may be sandwiched and held between the slot and the coil. . Thereby, it is possible to ensure electrical insulation between the stator core and the coil without winding the insulating paper member around the coil. However, this embodiment has an advantage in that the insulating paper member can be prevented from being displaced by winding the insulating paper member.

20 ... Coil 21 ... Stator 22 ... Rotor 23 ... Motor 41 ... Stator core 42 ... Teeth 43 ... Slot 44 ... Bottom 45 ... Split core 46 ... Yoke 46 ... Yoke 41 ... Stator core 53,54 ... Slot insertion part 55,56 ... Coil end part 67 ... Double-sided tape (regulating means) 80 ... Insulating paper member 80a ... Coil end insulating part (first insulating part) 80b ... slot insulating part (second insulating part) 80c ... overlapping part 83 ... connecting part 84 ... inner notch part (notch) 85 .. Outer notch (notch) S10: Coil forming step S20 ... Insulating paper member attaching step S30 ... Coil arranging step S40 ... Rotor arranging step

Claims (8)

A stator core formed in an annular shape by connecting a plurality of divided cores formed with teeth and yokes, and a coil partially inserted in a slot formed between the teeth of the adjacent divided cores. A stator,
A rotor disposed on the inner peripheral side of the stator and rotatably supported;
A motor having
The coil has at least a pair of slot insertion portions and at least a pair of coil end portions,
The coil end portion of the coil is insulated from the coil end portion of the adjacent coil by covering the entire circumference of the coil in the circumferential direction of the coil with an insulating paper member in at least a part of the cross-sectional central axis direction of the coil. Protected ,
The insulating paper member is
A first insulating portion covering the entire circumference of the coil end portion in the circumferential direction of the cross section;
A second insulating portion disposed along the slot insertion portion between the slot insertion portion of the coil and the slot of the stator core;
A connecting portion connecting the first insulating portion and the second insulating portion;
In addition, the unfolded shape becomes a band shape,
A plurality of the first insulating portions and the second insulating portions are alternately arranged along the longitudinal direction of the insulating paper member, and the adjacent first insulating portions and the second insulating portions are adjacent to each other. A motor connected by a connecting portion .   The motor according to claim 1,
  The coil end portion of the coil is provided so as to bulge outward in the radial direction of the stator,
  The motor according to claim 1, wherein the connecting portion of the insulating paper member is provided on the inner side in the radial direction. The motor according to claim 1 or 2,
The second insulating portion of the insulating paper member covers the entire circumference in the circumferential direction of the cross section of the slot insertion portion;
The width along the circumferential direction of the cross section when the first insulating portion is flattened and the width along the circumferential direction of the cross section when the second insulating portion is flattened have substantially the same width,
A motor having a notch in the connecting portion. The motor according to any one of claims 1 to 3,
The insulating paper member has an overlapping portion formed by overlapping one end portion and the other end portion in the circumferential direction of the cross section, and has a regulating means for restricting relative movement between the one end portion and the other end portion. A motor characterized by that. The motor according to claim 4,
The motor, wherein the overlapping portion of the insulating paper member is in contact with a bottom portion of the slot of the stator. A stator core formed in an annular shape by connecting a plurality of divided cores each having teeth and yokes, and a coil that is partially inserted into a slot formed between the teeth of adjacent divided cores and assigned to each phase A stator with
A rotor disposed on the inner peripheral side of the stator and rotatably supported;
A method of manufacturing a motor having
A coil forming step of forming the coil having at least a pair of slot insertion portions and at least a pair of coil end portions;
A first insulating portion that covers the entire circumference of the coil in the circumferential direction of the coil at the coil end portion, and is arranged along the slot insertion portion between the slot insertion portion of the coil and the slot of the stator core. a second insulating section, have a, a connecting portion for connecting the said first insulating portion and the second insulating section, together with the developed shape is a strip, the said first insulating portion in the longitudinal direction the Insulating paper member mounting in which a plurality of two insulating portions are alternately arranged and the insulating paper member connected by the connecting portion at a position where the adjacent first insulating portion and the second insulating portion are adjacent to each other is attached to the coil Process,
A coil placement step of inserting the coil into the slot after the insulating paper member mounting step;
A rotor arrangement step of inserting the rotor on the inner peripheral side of the stator;
A method for manufacturing a motor, comprising: It is a manufacturing method of the motor of Claim 6, Comprising:
The method of manufacturing a motor, wherein the second insulating portion covers the entire circumference of the slot insertion portion in the circumferential direction of the cross section. The motor according to claim 7,
In the insulating paper member mounting step, on the insertion side of the coil in the slot insertion portion to the slot, one end portion and the other end portion of the insulating paper member in the circumferential direction of the cross section are overlapped to form an overlapping portion,
In the coil arranging step, the overlapping portion is brought into contact with the bottom of the slot.

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